Weeping system for window screen corner keys

ABSTRACT

A corner key with a first and second leg each with an upper and lower portion. The corner key including a plurality of openings, formed in an indent on the upper portion of at least one of the first and second legs, for weeping water through the corner key.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates generally to a corner key weeping system to be used with a window, patio door and sliding door screens.

2. Background Information

A window or door screen consists of mesh or screening supported by a lightweight rectangular frame. The frame includes four essentially straight segments, i.e., the top, the bottom, and the left and right sides, which are connected at adjacent ends to form the corners of the frame. The ends are either cut at forty-five degree angles and connected directly together to form ninety-degree corners, or the ends are cut to mate with “corner keys,” which are corner shaped connectors. Each corner key basically consists of two legs with their adjacent ends joined at a ninety-degree angle to form a corner. The free ends of the legs fit within or over the adjacent end of the frame segments, to connect these segments via the corner, at a ninety-degree angle.

The screen may cover one-half of a double hung window or sliding door assembly. The screen frame thus slides either vertically or horizontally along tracks on the outer edges of the window or door jambs, to provide the desired coverage and, as appropriate, allow ingress and egress. Alternatively, the screen may be a full screen, with the screen frame covering the entire window or door opening. For installation and/or removal, the full screen frame tilts in or out of tracks on the outer edges of the window or door jamb. The installed full screen fits into the tracks by spring loading, such that the frame edges engage the tracks.

One problem with having a screen on the outside of a window or door is that water can collect between the screen and the window or door, and adversely effect the window or door assembly, and/or the underlying building structure. Prior solutions to this problem have elevated the bottom screen member above the window or door sill. This solution yielded an unattractive and unfinished appearance. In addition, with this solution homeowners could see daylight under the screen frame from inside the house because of this solution. Furthermore, when the window is open the elevated frame provides an opening for insects to enter the home.

SUMMARY OF THE INVENTION

The invention is an improved corner key with weeping holes, or openings, situated on at least one of the legs of the corner key. The openings are strategically positioned on the leg such that, when the corner key is included in a screen frame, the water may pass through the openings while the entire bottom section of the screen rests flush against the window or door sill. The openings extend along an inner wall of an indentation in the bottom leg of the corner key, and thus, the openings are not generally visible when the assembled screen is in place on the sill. The openings are also strategically sized, to allow water to drain sufficiently and yet prevent most insects from passing through.

The corner key may include openings on both legs, such that a given corner key can be used on either bottom corner of the screen frame.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and further advantages of the invention may be understood by referring to the following description in conjunction with the accompanying drawings, in which:

FIG. 1 depicts a window screen frame constructed in accordance with this invention;

FIG. 2 depicts a corner of the screen of FIG. 1 in more detail;

FIG. 3 is an exterior view of a corner key utilized in the frame of FIG. 1;

FIG. 4 is an interior view of the corner key of FIG. 3; and

FIG. 5 is an exterior view of an alternative corner key for use with an extruded aluminum frame.

DETAILED DESCRIPTION OF AN ILLUSTRATIVE EMBODIMENT

FIG. 1 depicts an exterior side of a screen 10 that is constructed in accordance with a first embodiment of the invention. The screen 10 includes a frame 14 that consists of four frame segments 14 a-d and interconnecting corner keys 16. The frame 10 supports screening 12 that mounts on the frame in a conventional manner, utilizing troughs 15 on the various frame segments.

Referring also to FIG. 2, at least one of the corner keys 16 contains a plurality of weeping holes, or openings 18, to allow water to drain through the corner key. The openings, which are formed in an inner wall 21 of an indent 20, are strategically positioned such that a bottom edge 22 of the corner key remains intact. Accordingly, the entire bottom edge 36 of the screen 10, which includes the frame segment 14 d and the two associated corner keys 16, sits flush on a sill 38 when the screen is in place. The bottom edge 36 of the screen, which includes the bottom edges 22 of the two corner keys, prevents daylight from being seen between the screen and the sill, and provides a finished appearance to the screen. Further, the bottom edge provides rigidity to the corner key. The sill 38 may be a window or a door sill. As shown the sill 38 includes a weep hole 39.

Referring now to FIGS. 3 and 4, the corner key 16 includes two legs 24 and 26 that meet at a ninety-degree angle to form a corner 28. The legs 24 and 26 consist, respectively, of upper sections 24 a, 26 a and lower sections 24 b, 26 b. The upper sections 24 a and 26 a are thicker then the lower sections 24 b and 26 b and meet to form a corner section 29, that has the same thickness as the screen frame sections 14 a-d (FIG. 1). Accordingly, each leg has a slight discontinuity, or side edge 30 and 31, where the upper and lower sections 24 a-b and 26 a-b meet. The thinner lower sections 24 b and 26 b slide into the ends of the adjacent frame segments, until the ends of the segments are flush with the corner section 29, that is, with the side edges 30 and 31, which operate as stops. The frame segments and the corner section then form an essentially continuous section of the frame 14.

The upper sections 24 a and 26 a of legs 24 and 26 further include U-shaped troughs 32 and 34, which align with the troughs 15 on the frame segments 14 a-d (FIG. 1), to facilitate the mounting of the screening 12 to the frame 14. In addition, the lower sections 24 b and 26 b may include shaped ends 24 c and 26 c with tabs 25 and 27, respectively. The shaped ends operate to hold the legs within the frame segments. Fins 29 may also be included to provide a tight fit within the screen frame, which because of manufacturer tolerances may be slightly wider or narrower.

Referring still to FIGS. 3 and 4, the upper sections 24 a and 26 a of the legs 24 and 26 include the indents 20 that contain the plurality of openings 18. The openings are formed on and extend the length of an inner wall 21 of the indent. The inner wall is parallel to the bottom edge 22 of the corner key, and thus, the openings are essentially hidden from the view of the homeowner.

As illustrated, the corner key has the openings 18 on each leg, and thus, the corner key may be used in either of the bottom corners of the screen frame. The corner keys may instead be manufactured with the openings on only one of the legs, such that a given corner key is appropriate for either a right or left bottom corner of the screen frame. Further, for convenience, the corner keys may be used in all of the corners of the screen frame as illustrated in FIG. 1. Alternatively, conventional corner keys may be used in the upper corners of the screen frame.

The corner key of FIGS. 3 and 4 include approximately six small opening 18. The respective openings are designed to be approximately 0.06″×0.12″ with areas of approximately 0.007 in². The approximate total area of the plurality of openings is thus 0.042 in². As is evident to one skilled in the art, there may be more or fewer openings, and the sizes of the openings may be larger or smaller.

The corner key 16 is used in a roll formed screen, that is, a screen in which the segments 14 a-d are made from roll formed aluminum.

FIG. 5 illustrates an alternative corner key 40 for use in a screen frame in which the segments 14 a-d are made from extruded aluminum. The screen frame formed with the extruded aluminum frame segments and the alternative corner keys is a particularly robust frame. The same reference numerals are used in the drawings for those features that are common to the corner keys 16 and 40.

The corner key 40 has legs 24 and 26 with lower portions 24 b, 26 b (shown in phantom) that are inserted into frame segments 14 a, 14 d and thicker upper portions 24 a, 26 a that meet to form a corner section 49. The corner section is sized to fit between the extruded frame segments, to give a more finished look to the frame. As shown, the legs include side edges 30 and 31 that act as stops for the extruded frame segments.

The upper portion 24 a, 26 a of at least one of the legs 24, 26 includes an indent 20 that contains the plurality of openings 18. Each indent 20 in the leg 24 and/or 26 includes an inner wall 21 on which the plurality of openings 18 are formed. The drawing illustrates an indent 20 on each of the two legs, such that the corner key may be used on either bottom corner of the screen frame.

For a more detailed discussion of the side edges 30, 31 and shaped ends 24 c and 26 c of the corner keys 16 and 40, refer to U.S. Pat. No. 5,547,011, entitled WINDOW SCREEN APPARATUS, which commonly owned, the teachings of which are expressly incorporated herein by reference.

The foregoing description has been limited to specific embodiments of this invention. It will be apparent, however, that variations and modifications may be made to the invention, for example, the openings may extend a partial length of the inner wall of the indent, there may be a single relatively large opening formed in the inner wall instead of a plurality of smaller openings, with the attainment of some or all of the advantages of the invention. Therefore, it is the object of the appended claim to cover all such variations and modifications as come within the true spirit and scope of the invention. 

1. A corner key for use in a screen, the corner key comprising: a first leg and a second leg each with an upper portion and a lower portion; and one or more openings on the upper portion of at least one of the first and second legs for weeping water through the corner key.
 2. The corner key of claim 1, wherein the one or more openings are placed slightly above a bottom edge of the corner key that sits flush against a sill when the corner key is incorporated into an installed screen.
 3. The corner key of claim 2, wherein the upper portions of at least one of the legs includes an indent and the one or more openings are formed in an inner wall of the indent.
 4. The corner key of claim 1, wherein each opening is approximately 0.007 in² in size.
 5. The corner key of claim 1, wherein the one or more openings includes approximately six openings.
 6. The corner key of claim 1, wherein the corner key is for use in forming the screen.
 7. The corner key of claim 1, wherein the one or more openings are included in the upper portions of both of the first and second legs of the corner key.
 8. The corner key of claim 1, wherein the lower portions of the legs are thinner than the upper portions and the legs include, where the upper and lower portion meet, side edges that act as stops.
 9. The corner key of claim 3, wherein the one or more openings are on the upper portions of both of the first and second legs of the corner key.
 10. The corner key of claim 9, wherein the lower portions of the legs are thinner than the upper portions and the legs include, where the upper and lower portion meet, side edges that act as stops.
 11. The corner key of claim 10 wherein the upper portions of the legs meet to form a corner section.
 12. A screen, comprising: four frame segments forming a top, a bottom, a first side, and a second side of the frame; corner keys for interconnecting the frame segments, with at least one of the corner keys including one or more openings for weeping water through the corner key.
 13. The screen of claim 12, wherein at least one corner key has a first leg and a second leg each with an upper portion and a lower portion, and the one or more openings are located on the upper portion of at least one of first and second legs of at least one corner keys.
 14. The screen in claim 13, wherein the one or more openings are located on the upper portions of both of the first and second legs of the corner key.
 15. The screen in claim 12, wherein the one or more openings are placed slightly above a bottom edge of the corner key that sits flush against a sill when the corner key is incorporated into an installed screen.
 16. The screen in claim 15, wherein the upper portions of at least one of the legs includes an indent and the one or more openings are formed in an inner wall of the indent.
 17. The screen in claim 8, wherein each opening is approximately 0.007 in² in size.
 18. A corner key, comprising: a first leg and a second leg each with an upper portion and a lower portion, the upper portion of at least one leg including a bottom edge that sits flush with a sill when the corner key is incorporated into an installed screen, the upper portion including an indent with an inner wall in which one or more openings are formed, the one or more openings sitting slightly above the bottom edge of the corner key.
 19. The corner key of claim 18 wherein the one or more openings consist of six openings and each opening is approximately 0.007 in² in size.
 20. The corner key of claim 18 wherein the upper portions of the legs meet to form a corner section. 